eo eptting an coping. evn he am of iene cnn ol publ VS - DEUTSCHER VERBAND FOR SCHWEISSEN UND \VERWANDTE VERFAHREN EX 1 Soope, 2 Canora requirements 3 Measures Detore wolding 4 4 Hated tool but welding 1+ Heated tool txt welding of pipes, pipeline component, ft fioge and shosts 42. Heated too bist welding of tapping toes 15 Blocrousion welding 151 Description of method 5.2. Welding ouipment 183. Preparation of welding 5 Welding procedure 6 Heated tool seckot welding 6.1, Descripon of method 62 Welding devices 65. Preparation of welding 64. Welcing procedure 7° Testing of walded joints 3 Vaid standaris and drecives ‘Apponctx: Processing instructions (shor versions) Welding protocols 1 Scope “This standard relates fo the heatod tool bull welding of shoots Aczeraing fo DIN 16225, tho haaled fool bull the heated tot Socket ard tho slectrotusion wolding of pipes, fitings and fapring tees made from PE-HD according o DIN 8074 and DIN 8075, DIN 10962, DIN Set2-4 and as42-1, boing used for the ‘conduction of gas bids ard sok, itr regard fo the folowing instructions, suitably wihin the melt flow rates MPR 190/5 0.39 fo 17 g/10 min may be assumed. “Tae into eoccunt ta casein ate malt ow index groups in Figure 1. Foe the heated tool butt welding of tapping tees Toctitione according to eoaton 4.2 ava tobe atenced pos and shoats within tho MEI groups 009, 020 and 022 the [MER value must bo contled (e.g. corilicate of the produce) Matoras outside the hatched area as wo as PE 100 requice an _adatonalprool 0 OVS 220-4, 2 General requirements “The ually of welding joints doponds on the qualification of the ‘waldar the sutabity of te usod equipment and devices a8 well ‘2s 0n cbesrvance (othe welding standatds. The welding joint can bo testod by means of nondostuctive andicr destructive smothecs. “The welding work must be monitored. Kind and range of _Suporvsing has tobe agroed batwoan the contract partners. cis Tecommenviod to reco the welding data in weidng protocals (Gamplo see appendix) or on data canons. Sedona paras ptton te sr rm 0B. Welding of Thermoplastics Heated tool welding of pipes, pipeline componente and sheets ihage fom PESHD Direction DVS 2207-1 Ce] (ugust 1065) Piss, pple component bterhr} a} ae 7 Wl rmveveernmeom Figure. Mos.tow ndox gu for PESHD acortng to DIN 16776- wae) intin the frame of the qualty assurance Ils recommended to perform and tast samples of pnts before begining anc during {he woking works Every welder has tobe tralnad and has tobe in possession of a valid qualfiation cea. The btended appieation range may be decisive ofthe kind of quafication. For the heated fool but ‘woldng of shoets ae woll'as in to Industral pong systom Conainiglon, tho standard DVS 2212-4 is val. For pipes S22smm outside dfameter an addtional. coticale of ‘ualfeaion is oqulod, “To traning and examination ofthe welding oaths doat with inthis document is dascilvod in tho rolovant recive OVGW GW ‘S20 which apples spocifialy forthe conctrucion of gas- and Wwaler pili. The diectve can bo analogously ueod as {uallicaton proof for the hated tool socket welding and tha lecrfusion welding In the industrial piping sysiom construction ‘The equipment and dovicos which aro used for wolng must ‘correspond to the requirements In Grective OVS 2208-1. The Wwolding of plastics for indoor appicatons Is describ in the quidsines OVS 1905-1 and DVS 1805-2. 3 Measures before welding ‘The welding rone must be protected against bad. woathor iniuences (eg. meiatur and tomperatures bolow + 5 °C). tie ‘enaured by sulablo measures (e.g. prebeatng, ten, heating) that the condone are stable for wading, work may be cari Dut al ary cuside temperature Insoler as the welder is not Pindoved In his handing I nocozsary. an addon proof muct be provided by carrying out sample welds undor the mentioned condtons (secton 7). It the soenifinished product f= heated up unevenly under intvence of sunshine, a tersperatura comporssation inthe area of tha wokdag jont ean be reached by covering. A coaling down ‘uring tha wong procass by ventilation has tobe avoidad, 0.0. by casing he piperands during welding, ‘Th pbteaon han boo ean up by gous of exponen’ apace wing nan None stony at cenionon le ecmmand, The ea wuld eee ee eee Sitar cas uct fs vrdon on anda a vba Tho Gmvochor ba ti Swe, DVS, Technical Committee, Working Group ‘Joining of Plastics" ‘Orders CS. GmbH, ® 0. Bx 10196540010 Dusetda, Gormany, Prone: +49(0}2119581-0, Teta + A90} 21/1591 180ee ee ae Pipos rom coke a oval immediately ater uncoting, The pipe ‘br must be prapared belore woiing, a 9. by careful heating uo (fi a hobair equipment and use ofa sulable camping andor Ferounding dovice. “Tho conection zonae ofthe compononts fo ba welded must be Undarnaged and have to be foe of contamination (2.9 dit, ol shavings) 4, Heated tool butt welding “41 Heated too! bt welding of pps, ppelae components, Milage snd obeste Deserptlon of method [At the noated tol butt welding mathod, the connacton zones of tho componants to be welded are aligned on the heated tool {atonmenil, heated up tothe welding Lomporaluce with reduced prossure (healng-up) and joined under presoure (ning) afer Femoval of tre healed tool (ool romoval). Figure 2 shows the principe f this procedure. [AK woldings must bo performed by means of machines and fsqupmont, wich covespond to the raqufemenis in DVS 220841 preparing manufacturer Infomation, calculated of moasured valves, ‘Adstonaly, at the welding of pips, tha workpiece moving fore esp. moving pressure ie faken from th indicator of te welding ‘machine dung the slow displacement of tha par to be wolded fad have tobe added 9 Bo prior dstermined [ening force resp. folnng pressure. “The nomloat wal thcknossas of the parts to be welded must 1000 20 e00 31500 «2000 32000 22500 32900 = 000 Figure 2. Prince of ha hata ol but weldng with exer pipe. 43.2 Preparation of welaing Porto tho stat ofthe welding process the welding temperature sat on tha hoatod too! fo be checked. This is done 0. 9. by mane ol fastndleaiing measuring device for tia measuisng of the eulace temperatura. The carol moaeuromont must ba dona ‘shia tho araa on the heated tool which corasponds to tha sari {ilshod product, For adjusting a thermic balance, the heated tol may ba insarted 10 minutes after reaching the set temperature at ‘re eartost. “To oneure an optimum welding connoction, the heated tool has to be cleaned wih an absorbent, norfuzzy and nor-coloured paper betora every walding oporaion. Tha ant-adhesive coating or Covering fe Peat Yet mst be oo of drags bn the working zone. ‘Tho jlning forces and joining prossures have tobe specitiod for tha machines to Da used. These can be based on ©. 9 ot, the gap width and the misalignment have to be contoed. ‘Tha mialgnrnent ofthe joining areas on the pipe culside resp. ahset may not pass the poissible size of 0.1 xwall icknes. ‘Too trosted welding arsas should be nether cited nor touched by hand, asa retreatment woud! be necessary then. Shavings {allen into the pipe have lo be removed. If the gap wiath of pips with targa outside diameter cannot be opt ascordng fo Tabla 1, ts allowed to achieve the contact of ‘tho parte on te haatoe toa! by mating of 413 Walding procedure In hosted too! ult woldng the welding aroas are hoated-up to the welding temperature by means offre healed {ool and joined Lndar prascue aftr amoving the heated tool. Tho heated toot tamperale Is 200 to 220 °C. in pancle the upper lemperatre lent i to aspited for smallor walthicknesses, the lower tormperature bt for bigger anes (see gure 9). The lifarent stages of the procoss ara lustratod in figura 4 eae 8 heated tol ternperature 335 waltickness tin Figure. Recommended values for te hosted tcl 1omparatie subjection walbiomess.) Poe eae ieee ieee eee hee ery [esserg ne Figure 4 Process tagan of hosod fo but wedng Alignment “The ining areas ofthe welding compononts are aligned to the hasted too! unt al areas aro pane-paraltelon tha haated tol, “Ths facts visi onthe Kind cf beads. The alignment i rished wnhen the bead heights have reached the monioned valuos in {able 2, coknn 2.0n the tral pipe cournferance resp. te total shect surface. The baad sizes aro an index for a completo Contact of the Joining areas on the haatod tool. At larger pipe dlamoters (> 890 mm) the sutlont bead size also on the ppe's Inside has to be contaled et he bacining ofthe welding works, Dossy by a test jin. The alignment prossurs of 0.18 Nine Steet dung a total agent process. Hoating-up For heating-up, the joining aroas must contact the heated tect tah iow pressure. ‘The pressure ls reduced 10 nearly zo (£0.02 Nim). Daring heatingup, the heat penetrates the Joining areaa end the Wolcig temperature is reached. Hoating- Up tmes are montionedin table 2, column 9, Removal of heated tool ‘After peating-vp, the joining areas are to be detached from the fhealed tool The heetod tool should bo withdrawn in such a way that tho heated jlning areas. aro nether caragod ner Covlaminated, The (pling arsas should be joined togather ‘uicky unt irecly botore the coniact. Tha changeover time ‘should be as short as possble (sea lable 2, column 4), a ‘otverwiae the plastid eroas wil col down, The welding joint ‘Quay woul bo infvenced negativay. aga Sto DVS 2207-4 grea arr tbat ut wl on are Jotning ‘hw areas fo be weldad should meet wit a speed of nearty zero. The cemanded joining presauro Is bult possibly linear. The required tmes are shown In table 2, column 5. The joining preseure 0.152001 Muro. “The jening proseure has fo be kept curing tho cooling timo (ceo {able 2, ectimn 8). Ralsed mocharical toads during or daly torte declaring ate alowed only after elongated cooing, Atos the joining, a regular double-boad must appear. The baad size shove the togualy of the weldings. Dillront boads could bo caused by diferent melt fow behaviour of tho connocted materia. K must always be larger than 0 (s98 gues). Shot vareon of processing instructions 680 appendtx 42 Hestad to! but welding of tapping te “The heatad foo! butt welding of tapping tes is useable with PE HO pipes according to DIN 8075 of maltslow index group 010. the case of PECHD pipes accorcing to molt ow indax group GOS the welding process 16 usaable only in conjunction wth a reinjoreoment embracing the pipe. The later condon also feppiee tf, eepocialy in tho cave of Sitios atlacned. at a subsequent stago, an attribution within the scope ofthis standard isnot possible, Hosted too! butt wads of tapping tees have tobe cariad outwith the help of welding furs. {Tbie2. Recommended valves forthe hesod ool but welding of ples, ngs and sheste made from PE-HD, alan outside loiprature of ‘pprotimatty 20°C ond toderate nr ow Onto vluea have tobe trpolted). i 2 a 4 = Nominal wall | Alignment Heatlng-up ‘thickness Bead neighton heated — | Heating-up time ‘ment timp (ligament with | (reating-up with 0.45 Nima) $0.02 Nim) en (rian value) tool atthe ond ofthe align | = 10 x walthickness Joining ‘Changeover Talaing Coottng tne under preseure | olning pressure build-up time | p=0.15 Nm? 20.01 ‘a maximum time rin (minimum values) 05 10 15 20 25 30 a5. 40 3 6 oc . 8.10 o. 10. a z 18. 10. 2. 12. % 6 . 4“. 20. 0.